High density pallet system

ABSTRACT

A pallet system for shipping a number of spools includes a pad which supports and retains a first layer of spools. A separator is disposed atop the first layer of spools and a second layer of spools is disposed atop the separator. Subsequent layers of spools and separators may be included in a stacked relationship, and a cap member is disposed atop the topmost layer of spools. The pad, cap, and separators form a stacked shipping unit and may include locking features and provisions for retaining straps.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of U.S. Provisional Patent Application61/473,374 filed Apr. 8, 2011, entitled “High Density Pallet System”,the contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates, generally, to packing systems. Morespecifically, the invention relates to pallet systems. In particular,the invention relates to pallet systems which allow for the high-densitypacking and shipping of cylindrical members such as spools of yarn,thread, or other filamentary material.

BACKGROUND OF THE INVENTION

Filamentary material such as yarn, thread, and the like is frequentlywound onto spools for shipping from a manufacturing facility to a usefacility. These spools generally are configured to fit directly into enduse manufacturing equipment. Typically, large numbers of wound spoolsare shipped to distribution or end use manufacturing facilities; hence,there is a need for a packing system which can securely retain suchspools for shipping. In addition to being simple to use, such shippingsystems should be light in weight, low in cost, and allow for thehigh-density packing of wound spools.

Goods are increasingly being shipped via containerized freight systemswhich utilize standard-dimension freight containers. Hence, any cargoshipping system should be configured to be compatible with standardfreight containers such that wasted space is minimized or eliminated,and maximum packing density achieved. Spools used for filamentarymaterials typically include a core portion about which the filamentarymaterial is wound, and in many cases, portions of this core project fromthe spool so as to allow mounting of the core onto use or processingequipment.

As will be explained in detail hereinbelow, the present inventioncomprises a palletized system which provides for the high-densitypacking of spool-wound material. The system of the present invention isconfigured to provide palletized stacks of spooled material which may bereadily handled by forklifts, cranes, and other such processingequipment, and which are dimensioned so as to allow for high-densitypacking in standardized shipping containers. These and other advantagesof the present invention will be apparent from the drawings, discussion,and description which follow.

BRIEF DESCRIPTION OF THE INVENTION

Disclosed is a pallet system for retaining a plurality of spools of thetype comprising a core having a filamentary material wound thereabout.The system includes a pad or pallet having a first face configured torest on a support surface and a second face having a plurality ofspool-engaging features defined thereupon. The spool-engaging featuresare each configured and operable to engage a spool so that the pad iscapable of supporting a layer of spools on its second face in apredetermined pattern. The system further includes at least oneseparator having a first and second face, each face having a pluralityof spool-engaging features defined thereupon in the predeterminedpattern. The system further includes a cap having a first face with aplurality of spool-engaging features defined thereupon in thepredetermined pattern. The components of the system are configured andoperable so that in the use of the system, the second surface of the padreceives and supports a first layer of spools thereupon in thepredetermined pattern, and the spool-retaining features of one of theseparators engages the first layer of spools. Further in the use of thesystem, a second layer of spools is supported on the second face of theseparator. In a typical application, a further number of separators andcorresponding layers of spools are added to the pallet system, and thecap member is then disposed atop the topmost layer of spools so that itsspool-engaging features engage those spools so as to form a completedshipping unit.

In particular embodiments, the spool-engaging features may compriseconical protrusions which engage the core portions of the spool. Inother instances, the spool-engaging features may comprise recesses whichreceive projecting portions of the cores of the spools. In furtherembodiments, the components of the pallet system may be configured todefine one or more grooves which operate to receive a strapping member.The cap and/or pad members may be configured to define further featuressuch as forklift access channels, stabilizing legs, forklift guides,lift pads for robotic devices, locking features, and the like.

The components of the pallet system may be fabricated from a polymericmaterial such as high molecular weight polyethylene, high-densitypolyethylene, low-density polyethylene, acrylonitrile-butadiene,-styrene, polypropylene, polyethylene, and combinations thereof. In someinstances the polymer may include a reinforcing material therein. Thepallet components may be formed by thermoforming. In some instances, thecomponents of the system may be configured so that the plurality ofspools may be disposed in a staggered matrix. In some embodiments, thefirst face of the pad component is configured so as to be engageablewith a second face of the cap so that completed shipping units may bereadily stacked atop one another.

Further disclosed is a method for packing a series of spools of materialthrough the use of the pallet system of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a spool of filamentary material;

FIG. 1B is a cross-sectional view of the spool of FIG. 1A;

FIG. 2A is a perspective view of one embodiment of pad member in accordwith the present invention, showing the first face thereof;

FIG. 2B is a top plan view of the pad of FIG. 2A showing the second facethereof;

FIG. 3A is a perspective view of an embodiment of cap in accord with thepresent invention showing the second face thereof;

FIG. 3B is a top plan view of the cap of FIG. 3A showing the first facethereof;

FIG. 4A is a perspective view showing a first face of a separator inaccord with the present invention;

FIG. 4B is a top plan view of the separator of FIG. 4A showing thesecond face thereof;

FIG. 5A is a perspective view of a palletized stack of spools utilizinga system of the present invention;

FIG. 5B is a cross-sectional view of the stack of FIG. 5A;

FIGS. 5C,5D and 5E are enlarged views of portions of the cross-sectionalview of FIG. 5B;

FIG. 6A is a plan view of a bottom surface of another embodiment of padmember of the present invention;

FIG. 6B is a cross-sectional view of a portion of the pad of FIG. 7Ashowing details of the spool-retaining feature;

FIG. 7A is a perspective view of another embodiment of cap member whichmay be utilized in the present invention, showing its first face;

FIG. 7B is a plan view of the cap member of FIG. 8A showing its secondface;

FIG. 8A is a perspective view showing a first face of another embodimentof separator in accord with the present invention;

FIG. 8B is a plan view showing a second face of the separator of FIG.9A;

FIG. 9A is a cross-sectional view of a palletized stack of spools inaccord with the second embodiment of the invention;

FIG. 9B is an enlarged cross-sectional view of a portion of the stack ofFIG. 10A; and

FIG. 10 is a perspective view of two stacked pallet units as configuredfor shipping, in accord with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The palletized system of the present invention includes components whichallow for the high-density stacking of a plurality of layers of woundspools. As such, the system includes a pad member, a cap member, and aplurality of separator members configured to be disposed therebetweenand retain a number of layers of wound spools. The system of the presentinvention may be configured in a variety of implementations, and someillustrative examples thereof are presented herein.

Referring now to FIGS. 1A and 1B, there is shown a typical wound spoolof the type which may be shipped utilizing the system of the presentinvention. FIG. 1A shows a perspective view of the wound spool 10showing the projecting core portion 12 and the filamentary material 14wound thereabout. FIG. 1B is a top plan view of the spool 10, and FIG.1B is a cross-sectional view of the spool. It is to be understood thatwhile these figures show a spool having a projecting core portion, thepallet systems of the present invention may also be used in conjunctionwith spools of a different configuration.

FIGS. 2A and 2B show various views of one particular embodiment of padcomponent (also referred to as a pallet member) of the system of thepresent invention. FIG. 2A shows the pad 16 in a perspective view, takenfrom its first (or lower) face, which will rest on a floor or othersupport surface in the use of the pad. FIG. 2B shows the pad in a topplan view as taken from its second (or upper) face, which in the use ofthe pad will support a plurality of spools thereupon. As will be seenfrom the figures, the pad includes a number of spool-engaging featuresdefined on its second face. The spool-engaging features, for examplefeature 18, engage and retain the spools in a predetermined pattern. Inthe FIG. 2 embodiment, this pattern comprises a three by four matrix andas such will support twelve spools. Other patterns are also within thescope of the invention. The pad member 16 is further configured toinclude notches which can accommodate strapping or other tie downs whichcan facilitate binding components of the system into a tight stack, andin the illustrated embodiment, these notches are shown at referencenumeral 20. The pad is also configured to accommodate a lift fork whenthe system is assembled. In this regard, the illustrated embodiment, asbest seen in FIG. 2A, includes pallet foot features 21 on its first facewhich define openings 22 configured to allow access to a lift fork.

Referring now to FIGS. 3A and 3B, there is shown an embodiment of capmember (also referred to as a cover member) which may be used in thesystem of the present invention. FIG. 3A is a perspective view of thecap member 26 showing a second (top) face, and FIG. 3B is a top planview showing the first (bottom) face of the cap. The cap member 26 has anumber of spool-retaining features 18 defined upon the second face in apredetermined pattern which corresponds to the same predeterminedpattern in the pad member. The cap 26 also includes notches 20 disposedand configured to retain a packing strap.

FIGS. 4A and 4B illustrate an embodiment of separator 28 which may beutilized in the present invention. FIG. 4A is a perspective view of theseparator 28, illustrating a first face thereof; and FIG. 4B is a topplan view of the separator showing a second face thereof. The separator28 includes a pattern of spool-engaging features 30 on both its firstand second faces. The spool-engaging features 30 are in a pattern whichcorresponds to the same pattern used in the cap and pad members. Asshown in FIG. 4, the spool-engaging features of this particularembodiment include a through hole, for example through hole 32. Thisthrough hole accommodates the projecting portions of the core of thespools as will be explained hereinbelow, and thus allows for higherdensity packing of spools in a stacked array. The separator 28 alsoincludes notches 20 which accommodate packing straps as discussed above.

FIG. 5A shows a perspective view of a palletized stack of spools 10utilizing the above-described system of the present invention. As willbe seen, a pad 16 forms the base of the stack, a cap 26 forms the top ofthe stack, and separators 28 retain spools 10 therebetween. FIG. 5Bshows the stack in a sectional view taken along line A-A in FIG. 5A. Aswill be seen, the through hole openings in the separators allow for thevery tight stacking of the spools.

Referring now to FIG. 5C, there is shown a partial, enlarged view of thestack shown in cross section in FIG. 5B taken at reference point 5C.FIG. 5C illustrates the manner in which the top cap 26 engages the spool10 and fits into the core portion thereof. FIG. 5D is a detail taken atpoint 5D in the FIG. 5B drawing and shows the separator 28 and themanner in which it is configured to allow projecting portions 12 of thespool 10 to fit therethrough so as to provide for a high-density stack.FIG. 5E shows a view taken at point 5E of the stack of FIG. 5B and showsthe bottom pad 16 in engagement with the spool 10. As will also be seen,the configuration of the bottom pad 16 accommodates the projectingportion of the core 12.

In view of the foregoing, it will be appreciated that the system of thepresent invention allows for the secure, high density, reliable stackingof spooled material. Various stacking configurations may be achievedthrough the use of various combinations of the aforedescribed pads,caps, and separators of the present invention so as to provide maximumfilling of shipping containers of differing sizes. As will be seen, thepads and caps may be further configured so that their outer faces canpositively engage one another so as to allow several stacked units eachcomprised of a pad, a cap, separators, and spools disposed therebetween,to be placed atop one another. By appropriately selecting the number oflayers and units, a stacked assembly may be prepared so as to fitstandard cargo containers. As will be understood in the art, thesestacks may be banded together by strapping material utilizing thenotches as previously discussed.

As mentioned above, the system of the present invention may beconfigured in a variety of embodiments, and another such embodiment isillustrated in FIGS. 6-10 which follow. The system of these figures isconfigured to retain a plurality of spools in a staggered relationshipin a four by four matrix, although other staggered configurations arereadily implemented utilizing the components of this embodiment.

FIG. 6A is a plan view showing a first face of a particular pad 16 ofthe system of the present invention, and features thereof whichcorrespond to the pad member previously described will be referred to bylike reference numerals. As in the previous embodiment, the pad includesa number of spool-engaging features defined on its upper (second) face,and one such spool-engaging feature is shown at reference numeral 18 inFIG. 6B is a cross-sectional view of one of the spool-engaging features18 as taken along line 6B-6B of FIG. 6A.

The pad member 16 is further configured to include features includinglid locks 50, pallet feet 52, and strapping detents as shown for exampleat reference numeral 54. The pallet may also include fork leveling pads,as shown at reference numeral 58, and these pads can aid in guiding aforklift and in that regard work together with associated fork openings22 as defined by the pallet feet 52. The pallet may further includerobotic vacuum lift pads as shown for example at reference numeral 56,and these pads provide a smooth surface which is engageable by a roboticlifting device.

FIGS. 7A and 7B show a lid or cap member 26 which may be utilized inconjunction with the pad or pallet member of FIGS. 6A and 6B. The capmember is shown in perspective view in FIG. 7A which illustrates thecap's first, spool-engaging, face. The cap member 26 has a number ofspool-retaining features 18 defined thereupon in a predetermined patternwhich corresponds to the same predetermined pattern in the pad member.FIG. 8B is a plan view of the cap 26 showing the second face thereof.The cap further includes robotic lift pads 58 as previously described,as well as pallet-engaging foot landing pads 60 which aid in stabilizingstacks of palletized goods. Lid locks 62 may be included, and strappingdetents 54 as previously described may likewise be included.

FIG. 8A is a perspective view, showing a first (front) face of aseparator 28 comprising a four by four staggered matrix, which may beemployed in combination with the aforedescribed pad and cap members.FIG. 8B is a plan view showing a second (back) face of the separator 28.The separator 28 includes a pattern of spool-engaging features 30 onboth its first and second faces disposed in a pattern which correspondsto the pattern of the cap and pad members. The separator 28 of FIGS. 8Aand 8B differs from the aforedescribed separator shown in FIGS. 4A, 4Band 5D insofar as it includes a number of large conical members 64 whichengage the spools to be loaded thereupon so as to facilitate loading ofthe assembly. The separator includes robotic vacuum lift pads 58 aspreviously described and can include notches or other features which areconfigured to accommodate packing straps.

Referring now to FIG. 9A, there is shown a cross-sectional view of anassembled, palletized stack of spools utilizing the pad, separators, andcap of the foregoing FIGS. 6-8. As will be seen, the stack is comprisedof a cap 26, a pad or pallet 16, and seven stacked four by four arraysof spools 10 wherein each of the layers of spools is separated from theothers by a separator 28.

FIG. 9B is an enlarged view of a portion of the cross-sectional view ofFIG. 9A, showing portions of two stacked spools 10 with a portion of aseparator 28 therebetween, and specifically illustrating the manner inwhich the cone feature 64 projects into a portion of the spool 10. FIG.9B also shows a portion of a conical feature 66 of a cap memberprojecting into the spool. As will be appreciated, the configuration ofthis embodiment of the present invention provides for a densely packed,mechanically stable stack of spools.

FIG. 10 shows a perspective view of a fourteen-layer stack of spoolsemploying the system of the present invention. As will be seen, thestaggered relationship of the spools will allow stacks to be interfitwhen disposed in a shipping container so as to maximize the amount ofspace which is filled. The fourteen-layer stack of FIG. 10 is comprisedof two units, each of which includes a pad 16 and a cap 26 member. Afirst seven-layer stack 70 has a second seven-layer stack 71 placedthere atop, and in this regard, the pad member 16 of the second stack 71is configured to engage the cap member 26 of the first stack 70.

In general, the pad, cap, and separator members are fabricated frompolymeric materials, since such materials are generally low in cost,high in strength, lightweight, and dimensionally stable. Some specificpolymeric materials utilized to fabricate these members include highmolecular weight polyethylene, high-density polyethylene, low-densitypolyethylene, acrylonitrile-butadiene-styrene (ABS), polypropylene,other polyethylenes, and various combinations of the foregoingmaterials. As is known in the art, the polymers may include reinforcingmaterials such as fibrous materials therein as well as fillers, coloringagents, and the like. In specific instances, the components arefabricated from thermoplastic polymers utilizing various molding orshaping processes. In one specific instance, the components arefabricated by thermoforming polymeric stock. In other instances, theymay be fabricated by injection molding or other such processes. In yetother instances, the components may be manufactured from thermosettingpolymeric materials or curable resin materials. All of suchimplementations are within the scope of the present invention.

The foregoing describes some specific implementations of the presentinvention. Other implementations, modifications, and variations thereofwill be apparent to those of skill in the art. The foregoing drawings,discussion, description, and examples are illustrative of specificembodiments of the present invention but are not meant to be limitationsupon the practice thereof. It is the following claims, including allequivalents, which define the scope of the invention.

1. A pallet system for retaining a plurality of spools, each spoolincluding a core having a filamentary material wound thereabout, saidsystem comprising: a pad having a first face configured to rest upon asupport surface and a second face having a plurality of spool-engagingfeatures defined thereupon, each spool-engaging feature being configuredand operable to engage a spool so that said pad is capable of supportinga layer of said spools on said second face in a predetermined pattern;at least one separator having a first and second face, each face havinga plurality of spool-engaging features defined thereupon, saidspool-engaging features each being configured so as to engage a spool,said spool-engaging features being disposed in said predeterminedpattern; a cap having a first face having a plurality of spool-engagingfeatures defined upon said first face thereof, said spool-engagingfeatures being disposed and operable so as to engage said spools in saidpredetermined pattern; wherein said pad, said at least one separator,and said cap are configured and operable so that in the use of saidsystem, said second surface of said pad can receive and support a firstlayer of spools thereupon in said predetermined pattern, and thespool-engaging features of a first one of said at least one separatorengage said first layer of spools, and wherein a second layer of spoolsmay be supported on the second face of said one of said at least oneseparators; and wherein said spool-engaging features of said cap canengage a layer of spools supported on either the second face of saidfirst one of said at least one separators, or on a second face ofanother one of said at least one separators.
 2. The pallet system ofclaim 1, wherein the spool-engaging features of at least one of saidpad, said at least one separator, and said cap are each configured toproject into the core of a spool.
 3. The pallet system of claim 2,wherein said spool-engaging features which are each configured toproject into the core of a spool comprise conical features.
 4. Thepallet system of claim 1, wherein the spool-engaging features of atleast one of: said pad, said at least one separator, and said cap areeach configured so as to engage a spool and permit a portion of thelength of the core of said spool to project thereinto.
 5. The palletsystem of claim 1, wherein said spool-engaging features which are eachconfigured to permit a portion of the length of the core of said spoolto project thereinto comprise openings defined in a respective one ofsaid pad, said at least one separator, and said cap.
 6. The system ofclaim 1, wherein said pad, said at least one separator, and said cap areformed from a polymeric material.
 7. The system of claim 6, wherein saidpolymeric material is a thermoformed polymeric material.
 8. The systemof claim 6, wherein said polymeric material is selected from the groupconsisting of high molecular weight polyethylene, high-densitypolyethylene, low-density polyethylene, acrylonitrile-butadiene-styrene,polypropylene, polyethylene, and combinations thereof.
 9. The system ofclaim 6, wherein said polymeric material includes a reinforcing agenttherein.
 10. The system of claim 1, wherein the first face of said padis configured to be engageable by a lift fork.
 11. The system of claim1, wherein at least one of said pad, said at least one separator, andsaid cap include a notch therein configured to engage a binding strap.12. The system of claim 1, wherein said first face of said pad isfurther configured so as to be engageable with a second face of said capwhich second face is opposite the first face thereof.
 13. The system ofclaim 1, wherein at least one of said pad, said cap, and said separatoris configured to be gripped by a robotic lifter.
 14. The system of claim1, wherein said spool-engaging features define a staggered matrix.
 15. Amethod for packing spools, each spool including a core having afilamentary material wound thereabout, said method comprising: (a)providing a pad having a first face configured to rest upon a supportsurface and a second face having a plurality of spool-engaging featuresdefined thereupon, each spool-engaging feature being configured andoperable to engage a spool so that said pad is capable of supporting alayer of said spools on said second face, in a predetermined pattern;(b) disposing a first plurality of spools on said pad so that each ofsaid spools is engaged by a respective one of said plurality ofspool-engaging features of said pad; (c) providing a first separatorhaving a first and second face, each face having a plurality ofspool-engaging features defined thereupon, said spool-engaging featureseach being configured so as to engage a spool, said spool-engagingfeatures being disposed in said predetermined pattern; (d) disposingsaid first separator so that said spool-engaging features of said firstface each engage a respective one of said spools of said first pluralityof spools; (e) disposing a second plurality of spools on said secondface of said first separator so that each of said spools is engaged by arespective one of said plurality of spool-engaging features of thesecond face of said first separator; (f) providing a second separatorhaving a first and second face, each face having a plurality ofspool-engaging features defined thereupon, said spool-engaging featureseach being configured so as to engage a spool, said spool-retainingfeatures being disposed in said predetermined pattern; (g) disposingsaid second separator so that said spool-engaging features of said firstface each engage a respective one of said spools of said secondplurality of spools; (h) disposing a third plurality of spools on saidsecond face of said second separator so that each of said spools isengaged by a respective one of said plurality of spool-engaging featuresof the second face of said second separator; (i) optionally, repeatingsteps (f)-(h) one or more times utilizing at least a third separator andat least a fourth plurality of spools; (j) providing a cap having afirst face having a plurality of spool-engaging features defined uponsaid first face thereof, said spool-engaging features being disposed insaid predetermined pattern; and (k) disposing said cap so that saidspool-engaging features of said first face each engage: a respective oneof said spools of said third plurality of spools, or a respective one ofsaid spools of said at least a fourth plurality of spools.